Projectile, projectile core, and method of making

ABSTRACT

A projectile core is provided formed from a carrier and a colorant. The carrier and colorant are mixed into a core mixture, which is formed into a predetermined core shape. The core mixture is cured until substantially firm, such as by drying, heating or freezing. An outer layer may be formed adjacent the surface of the projectile core by heating. An outer coating may also be applied to the projectile core. A method of forming a projectile core comprises: (a) mixing a carrier and a colorant to form a core mixture; (b) forming the core mixture into a predetermined core shape; and, (c) curing the core mixture until a substantially firm projectile core is formed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.11/726,947, filed Mar. 23, 2007 which is a continuation of U.S. patentapplication Ser. No. 10/579,002, filed May 11, 2006, which is a §371U.S. National Phase of International Patent Application No.PCT/US2004/037946, filed Nov. 12, 2004, which claims the benefit of U.S.Provisional Application Nos. 60/519,307 and 60/525,394 filed Nov. 12,2003 and Nov. 26, 2003, respectively, which are incorporated byreference as if fully set forth.

FIELD OF THE INVENTION

The present invention is directed to an improved marking projectilecore, a marking projectile and method of making same.

BACKGROUND

In recent years, the popularity of the combat game known as “Paintball”has increased dramatically. Paintball is now a recognized and popularsporting activity. In one form of this game, players on two teams areeach supplied with a paintball marker (paintball gun) and a number ofmarking projectiles, or “paintballs,” which are rounds of ammunition.The terms “projectile” and “marking projectile” are usedinterchangeably. The projectiles comprise a spherical gelatin or starchshell filled with a non-toxic, water-soluble, biodegradable paint(referred to herein “liquid dye”). Paintball markers fire thesepaintballs using compressed gas (e.g. CO2, N2, etc.) as a propellant.When a player is hit with a paintball, the paintball ruptures,“painting” or “marking” the target providing dramatic evidence of thehit, without injuring the player.

Soft and hard capsules, shells or casings have been used in the sportsand leisure fields, as well as in law enforcement and military training,with liquid dye formulations within projectiles adapted to rupture uponimpact with an intended target. Generally, such projectiles have thephysical properties in which the casing is hard and impact resistantenough to survive normal loading and firing forces, while at the sametime adapted to rupture and release the liquid dye composition upon highvelocity contact with a target surface. Thus, known marking projectilesare essentially a capsule or shell filled with a liquid. The capsule orshell defines the shape of the projectile, and the fill material, whichis a liquid or semi-solid, is shapeless or amorphous, and moves withinthe capsule or shell.

Some currently available liquid dye compositions used in paint ballscontain a dye in conjunction with hydrophilic carriers containing amixture of high and low molecular weight polyethylene glycols (PEG).Among the disadvantages associated with currently available dyecompositions include tenacious or permanent staining of target fabrics,freezing and solidification of the dye composition during exposure tocolder temperatures, separation and precipitation of dye compositioningredients during storage, and a thin consistency. Various liquid dyesare discussed in U.S. Pat. No. 6,530,962, which is incorporated byreference.

A marking projectile impacts a target at a high velocity, which producesan impact force upon the projectile. Projectiles are formed so that theshells do not rupture until a sufficient impact force is imparted.

Currently available projectiles formed from gelatin or starch shells andfilled with marking liquid dye suffer various deficiencies, both inmanufacture, and in use. These types of paintballs are expensive tomanufacture, and may suffer breakage problems. Known projectile filledwith liquid dye also suffer from accuracy problems, as the liquid dyetends to shift during flight.

While gelatin capsule or starch shell production may be expensive andtime consuming, there currently exists an abundance of agriculturalbiomass, which may be defined as the biodegradable fraction of products,waste and residues from agriculture, or as plant material processingwaste. Various types of biomass are discussed in U.S. Pat. No.5,171,592, which is incorporated herein by reference. In particular,there is an abundance of cellulosic fibrous material produced as a wastebyproduct of agriculture. For example, rice straw is produced throughoutthe world as a byproduct of rice cultivation. The options for thedisposition of rice straw are limited by the great bulk of material,slow degradation in the soil, harboring of rice stem diseases, and highmineral content. Fields must be cleared of rice straw to make way forthe next crop. Accordingly, alternate uses are sought for rice straw andother biomass.

Many pigments, powders, emulsifiers and binders are also freelyavailable and inexpensive, and used in many industries. Powders areuseful for their absorbent properties and their compactability, andpigments are useful for their colorant properties.

There exists a need for improved technology relating to markingprojectiles.

In particular, there is a need to improve the attributes of projectiles,by providing a projectile that is efficient to manufacture, low cost,and safe to the environment.

There is yet a further need for a projectile that is formed other thanas a liquid filled capsule.

In addition, there exists the need for a paintball formed from freelyavailable materials that may be acquired and processed at low cost.

SUMMARY OF THE INVENTION

The present invention is directed to a novel projectile core, aprojectile having the novel core of the present invention, and a methodof making the same.

A projectile core according to the present invention generally comprisesa carrier mixed with a colorant, formed into a predetermined projectilecore shape. The projectile core is substantially firm, and retains itsshape prior to impact with a target. Upon impact with a target, theprojectile core at least partially disintegrates or disperses, markingthe target with the color of the colorant. In a preferred embodiment,the carrier is a fibrous, absorbent material, such material capable ofabsorbing liquid dye. The projectile core of the present invention canthen be coated or sealed to form a projectile of the present invention.

In another embodiment of the present invention, the carrier is a powder.The powder is blended with a colorant, and formed into a predeterminedprojectile shape.

An outer coating may be applied to the projectile core, forming theouter coating, and finishing the projectile. The outer coating may beapplied by any acceptable method, including, but not limited tospraying, vat immersion, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a diagrammatic cross sectional view of a projectile core ofthe present invention.

FIG. 2 is a diagrammatic representation of the combination of materialsto form a mixture used in a core of the present invention.

FIG. 3 is a diagrammatic representation the addition of a carrier to acolorant.

FIG. 4 is a diagrammatic cross sectional view of a molding process forforming a projectile core of the present invention.

FIG. 5 is a diagrammatic cross sectional view of an alternate moldingprocess for forming a projectile core of the present invention.

FIG. 6 is a diagrammatic cross sectional view of another embodiment of aprojectile core of the present invention.

FIG. 7 is a diagrammatic cross sectional view of a further alternatemolding process for forming a projectile core of the present invention.

FIG. 8 is a diagrammatic cross sectional view of another embodiment of aprojectile core of the present invention.

FIG. 9 is a diagrammatic cross sectional view of another embodiment of aprojectile core of the present invention.

FIG. 10 is a diagrammatic cross sectional view of a curing process forforming a projectile core of the present invention.

FIG. 11 is a diagrammatic cross sectional view of an embodiment of aprojectile of the present invention.

FIG. 12 is a schematic representation of a mixture of materials to forman alternate embodiment of a projectile core of the present invention.

FIG. 13 is a diagrammatic cross sectional view of an alternateembodiment of a projectile core of the present invention.

FIG. 14 is a diagrammatic cross sectional view of a molding process toform an alternate embodiment of a projectile core of the presentinvention.

FIG. 15 is a diagrammatic cross sectional view of a molding process toform an alternate embodiment of a projectile core of the presentinvention.

FIG. 16 is a diagrammatic cross sectional view of another embodiment ofa projectile of the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT(S)

Referring to the figures wherein like elements are represented by likenumerals, FIG. 1 depicts a projectile core 10, having a carrier 12. In apreferred embodiment, the carrier comprises an absorbent material. Theabsorbent material is preferably a fibrous, absorbent material, such asa cellulosic material, or an absorbent powder, each of which isdiscussed in detail below. The projectile core 10 further comprises acolorant 14 for marking a target. As shown by FIG. 2, the carrier 12 andcolorant 14 are mixed or otherwise blended to form a core mixture 16.

A novel aspect of the projectile core 10 of the present invention, isthat the carrier 12 or core mixture 16 is shaped into a predeterminedcore shape prior to coating or sealing. As used herein, thepredetermined core shape refers to the overall shape of the projectilecore 10. The predetermined core shape is formed prior to any optionalcoating or sealing of the projectile core 10. The projectile core 10,once formed into the predetermined core shape, is at least partiallycured, either with ambient air, heat, or cold, until it is substantiallyfirm. As used herein, the term “substantially firm” is used to designatea state whereby the projectile core 10 generally retains itspredetermined core shape prior to impact with a target. Thepredetermined core shape is not defined by, or otherwise a function of,any outer coating, capsule, or shell. The projectile core 10 of thepresent invention may be adapted to support a coating, wherein thecoating conforms to the predetermined core shape. The predetermined coreshape is preferably a sphere, such as for use in the sport of paintball.Upon impact, at least a portion of the projectile core 10 disperses ordisintegrates, marking the color of the selected colorant 14 on thetarget.

Fibrous, Absorbent Material

In one embodiment, the carrier 12 is a cellulosic material, capable ofabsorbing a colorant 14. The colorant 14 may be a pigment, a liquid dye,a powder dye, a water soluble dye, a permanent dye, an infra red dye, anultra violet dye, a “disappearing” ink or dye that initially marks andfades over a period of time, or a dye that glows in the dark, and anyequivalents or substitutes. The combination of the carrier 12 and thecolorant 14 is referred to herein as the core mixture 16. The carrier 12or core mixture 16 is formed into a predetermined core shape forming aprojectile core, which preferably has a spherical shape, and is sizedand weighted for use as a marking projectile. As used herein, the term“marking projectile” or “projectile” are used interchangeably, anddescribe a projectile which at least partially disintegrates ordisperses and marks a target upon impact, being useful in the sport ofpaintball, as well as by military or law enforcement training.

The projectile core 10 comprises a colorant 14 for marking a target. Thecolorant 14 in a paintball, by way of example, is a liquid dye that isnon-toxic and non-caustic, water-soluble and usually formed frombiodegradable or naturally-occurring ingredients. Colorant 14, as usedherein, refers to any of the known liquid dyes, such as food colorings,or other water-soluble, non-toxic marking liquids, sometimes referred toas “paint,” used in the sport of paintball, or in connection withnon-lethal rupturable marking projectiles such as those used by lawenforcement such as, for example, training. Food dyes (pigments) andpolyethylene glycol, may be used. The liquid dye may also be a mixtureof propylene glycol, sorbitol, color dye and wax.

Certain cellulosic material is recovered as agricultural waste, whichcan also be termed biomass. As used herein, the terms “cellulosicmaterial” and “cellulosic materials” refer to any of the fibrousmaterials containing cellulose, including materials characterized aslignocellulose or hemicellulose. The cellulosic material can be anysuitable fibrous substance or substances that will absorb the colorant14. For example, typical cellulosic materials for use in the presentinvention include, but are not limited to, agricultural fiber such asrice straw, wheat straw, or combinations thereof. Cellulosic materialsinclude the biomass of aspen chips, sawmill and logging residues, wheatstraw, wheat chaff, barley straw, rice straw, corn stover, sugarcanebagasse, kochia stems, and the like. However, no specific source ofcellulosic material is required. Preferably, the cellulosic materialabsorbs a liquid dye.

There are a variety of nonwood plants which produce fibers havingabsorbent properties. These nonwood plants are often referred to in theart as “agricultural residues” or “fiber crops”. Examples of plants foreach of these categories include agricultural residues fiber cropsincluding: wheat straw, kenaf, rice straw, industrial hemp, corn stalks,sisal bagasse (sugar cane), textile flax straw, rye grass, straw,Hesperaloe, seed flax, straw flax, and straw.

The cellulosic material usable for the present invention may be alignocellulose material selected from plant fiber materials includingwood pieces, wood meals, wood fibers, wood chips, veneer scraps, plywoodscraps, waste-paper, pulps, rice straw, rice hulls, kaoliang straw,bagasse, bamboo, and wheat straw.

The preferred cellulosic material is rice straw. Rice straw is a fibrouscomposition, capable of absorbing liquid such as the liquid dyenecessary for use in the sport of paintball. Rice straw is resistant tobacterial decomposition and therefore suitable to serve as a projectilecore, which will be stored and may not be used immediately.

Other cellulosic materials may be used for the carrier 12 as analternative to rice straw, including but not limited to straws, grasses,palm waste, wheat straw, plant waste or paper mill waste, corn stover,kenaf, industrial hemp, sisal, rye grass straw, wheat straw, bagasse,hesperaloe, flax straw, non-woody fibers liberated from sugar cane,bagasse, sabai grass, banana leaves, paper mulberry (i.e., bast fiber),abaca leaves, pineapple leaves, esparto grass leaves.

Lignocellulose refers to plant materials made up primarily of lignin,cellulose, and hemicellulose. Examples of suitable materials are wood,wood flour, wheat straw, rice straw, corn straw, hemp, dried grass, ricehulls, bagasse, flax, stalks of other plants such as soya, cottonincluding recycled and shredded cotton fabrics, shredded regeneratedcellulose fibers and fabrics such as rayon, shredded paper, etc. Also,recycled fibers which may contain any of the above cellulosic materialsin different percentages can be used in the present invention.

All of the above materials are referred to herein, individually or incombination, as “cellulosic material” or “cellulosic materials.” As usedherein, the terms “carrier” includes any of the above-listed cellulosicmaterials or combinations thereof, as well as any other fibrous,absorbent materials having properties desirous for the formation of aprojectile core as described herein. Rice straw is used as the primaryexample of a cellulosic material used for the carrier. In oneembodiment, the projectile core of the present invention is formed frommaterials that are capable of carbonizing, such as by heating or partialburning. Those materials which carbonize and thicken when exposed toheat are preferred, as described in greater detail below.

As shown in FIG. 3, the carrier 12 is introduced to a colorant 14, whichis absorbed by the carrier 12. The core mixture 16 is essentially amixture of: the carrier 12, such as the rice straw as the fibrous,absorbent material, and the colorant 14. Other materials, ingredients oradditives, such as binders, surfactants, emulsifiers, or desiccants, maybe incorporated into the core mixture 16 to achieve desired properties,or to increase the performance or properties of the projectile core ofthe present invention.

The carrier 12 may be ground, granulated, compacted, or otherwisepulverized prior to introduction of the colorant 14. Any method ofgrinding, compacting, granulating, or pulverizing the carrier 12 isacceptable. The carrier 12 may also be dried to remove moisture. By wayof example, the porosity of rice straw may be controlled by grinding anddrying. It is possible to produce a core mixture 16 formed from ricestraw as a carrier 12, where the void fraction is up to 80% of thevolume of the core mixture 16.

The colorant 14 may be introduced to the carrier 12 in any acceptablemethod whereby an amount of colorant 14 will be absorbed by the carrier12. For example, where the colorant 14 is a liquid dye, an amount ofliquid dye may be introduced to the carrier 12 via soaking the carrier12 in the liquid dye, dipping the carrier 12 into the liquid dye or aliquid dye bath, spraying the liquid dye onto the carrier 12, or theliquid dye may be injected into the carrier 12, or the liquid dye may bepoured into an amount of the carrier 12, thus forming the core mixture16. The core mixture 16 may be mixed or otherwise blended, such as toproduce a substantially uniform distribution of color throughout thecore mixture 16. Mixing the carrier 12 and a liquid dye, or other liquidcolorant 14, produces a core mixture 16 which is a semi-solid or slurry,that may be molded, shaped, stamped, compacted, or otherwise formed intoa predetermined core shape for a projectile core 10 and/or a projectile18, as described in further detail below. Upon curing the core mixture16, the projectile core 10 comprises a substantially firm mass thatretains the predetermined core shape of the projectile core 10 untilimpacting a target. In an alternate embodiment, the core mixture 16 isof such a dryness that it may be formed into the substantially firmprojectile core 10 without further curing.

In one embodiment, the carrier 12 is ground, granulated, compacted, orpulverized, and then shaped by a mold to form the predetermined coreshape of the projectile core 10, prior to the addition of the colorant14. Alternately, the colorant 14 may be added to the carrier 12 prior tomolding or shaping. The carrier 12 or core mixture 14 is formed into thepredetermined core shape and size of a projectile 18 by molds, by theuse of a press, by stamping, by dies, or any other suitable means. Asshown by FIG. 4, the carrier 12 may be placed between first and secondmold halves 20 a, 20 b forming two halves of a projectile, which arebrought together, capturing the carrier 12 within the mold portions 20a, 20 b.

In one embodiment of the invention, the projectile core 10 is made bygrinding, granulating, compacting, or pulverizing the carrier 12 into aparticulate, granular or powdery substance. Colorant 14, such as aliquid dye, is added to the carrier 12, forming the core mixture 16.Binders such as cellulose, gelatin, plasticizers, various gums, waxes,cellulose derivatives, gelatin, lignin, PVP, PVA and a complex magnesiumsilicate and lubricants such as metal stearates, fatty alcohols, fattyacids and/or oils, oils, butters, lipids, surfactants, starch, dextrin,sodium alginate, sodium acrylate, polyvinyl pyrrolidone, amonosaccharide or an oligosaccharide such as sucrose, lactose, oracceptable substitutes of these materials, or combinations thereof, maybe added to the core mixture 16, to adjust the properties of the coremixture 16. Emulsifiers may also be added to the core mixture 16.

It is appreciated that the colorant 14 may be introduced to the carrier12 before or after the carrier 12 is formed into the desired finalprojectile core shape, or may be introduced during each of those steps.Thus, as discussed, the colorant 14 may be added to granulated, groundor pulverized carrier 12 prior to shaping. Alternately, the colorant 14may be introduced to the carrier 12 after the carrier 12 has beenshaped. The carrier 12, previously formed into the predeterminedprojectile core shape such as a sphere, may be introduced to colorant14, for a selected period of time, whereby the carrier absorbs theliquid dye. Any acceptable method of incorporating or otherwiseintroducing the colorant 14 to the carrier 12 may be used, such asspraying, dipping, or using a bath. Furthermore, the liquid dye may beadded to the carrier 12 by injecting the colorant 14 into a mold 20during formation of the projectile core 10.

By way of example, a projectile according to the present invention maybe formed by a mold. In this example, mold 20 may have mold portions 20a, 20 b, each mold portion having a cavity 22 that has a contour,defining the final projectile core shape. In the case where thepredetermined core shape is a sphere, so that a spherical projectile 18is formed, each mold portion 20 a, 20 b defines half of a sphere.However, it should be readily apparent that the cavities can be formedinto any desired projectile shape, so that the core (and resultingprojectile) need not be spherical in shape.

The mold portions 20 a, 20 b are brought together, capturing a quantityof carrier 12 or core mixture 16 (FIG. 5), within the mold 20 to form aprojectile core 10. The mold may then be heated, such as by an externalheat source or by utilizing molds that include heating elements, to cureand harden the carrier 12 or core mixture 16 to a desired firmness.Alternately, the shaped projectile core 10 may be removed from the mold,and cured, such as by heating or drying, for example, by baking, heatlamps, or any other acceptable curing means. The mold and core mixture16 may also be dried by ambient air, to produce a projectile core 10that is substantially firm. It is appreciated that the projectile core10 may have portions, such as adjacent the inner portion 36, that remainwet or soggy, particularly where a liquid dye is used as the colorant14. However, the projectile core 10 of the present invention is cured sothat it is substantially firm whereby it retains its overallpredetermined core shape, regardless of these inner wet or soggyportions.

It is appreciated that any type of mold capable of shaping the coremixture 16 may be used to produce a projectile core 10 of apredetermined core shape according to the present invention. The carrier12 or core mixture 16 in any desired state of dryness may be compactedby use of molds, presses and/or dies into the desired shape, density andsize.

There may be standard industry sizes that are used to determine thesize, weight, or other dimensions of the projectile core 10. Generally,marking projectiles in the sport of paintball, or paintballs, come insizes ranging from .40-.75 caliber (inches diameter), with the commoncaliber being .68 (0.68 inches diameter), or an approximation of .68caliber. An average paintball weighs between approximately 2.5 g and 4g. Accordingly, the projectile core 10 may be formed to .68 caliber, andthe weight may be adjusted to between approximately 2.5 g to 4 g, andpreferably 2.8 g to 3.5 g, so that a projectile 18 formed having aprojectile core 10 according to the present invention operates withknown paintball markers, paintball hoppers, and other equipment.

FIG. 7 depicts an alternative method wherein a carrier 12 such as ricestraw, or core mixture 16, is injected via a channel 24 into mold 26,having separable portions 26 a, 26 b. The mold portions 26 a, 26 b areheated thereby drying, to any desired amount, and setting the carrier orcore mixture in order to retain the shape defined by the cavity 28 ofthe mold 26.

FIGS. 6, 8, and 9 depict cross sections of various examples ofprojectiles 18 and projectile cores 10 of the present invention. Inaddition to any other curing, the application of high temperature to theoutside of the projectile core may be used in order to sear, burn,carbonize, or otherwise singe the outer surface 30 of the projectilecore 10, forming an outer layer 32 of the projectile core 10 that ishardened, crisp and/or brittle, in comparison to the other portions ofthe projectile core 10. The outer layer 32 comprises the portion of theprojectile core 10 adjacent the outer surface 32 that has hardened inrelation to the other portions of the projectile core nearer the center34 of the projectile core 10. The thickness of the outer layer 32 may becontrolled by controlling the time of exposure to heat, the carrier 12selected, any other ingredients added to the core mixture 16, or otherfactors.

In one embodiment, depicted in FIG. 9, where high temperature is appliedto the outer surface 30 and an outer layer 32 is formed, the innerportion 36 of the projectile core 10 may remain wet, moist, or soggy.Thus, when a projectile 18 formed having such a projectile core 10 isshot from a projectile marker and impacts a target, the outer layer 32will disintegrate, disperse, burst and/or crack upon impact, and theinner portion 36 of the projectile core 10, which is a moist, coloredmass, will hit the target producing a “splat,” marking the target.

As shown in FIG. 8, the core mixture 16 that has been formed into thedesired shape of a projectile 18 is cured until a substantially firmprojectile core 10 is formed. In another embodiment of the presentinvention, the projectile core 10, once formed, may be cured until theprojectile core 10 is essentially dry. In this case, essentially drydoes not mean completely free of all moisture, but instead refers to astate where the core is no longer wet or soggy. The projectile core 10may also be cured until it reaches a chalky or powdery state throughout.Upon impact, such a projectile core 10 will at least partiallydisintegrate or disperse, producing a dry powder “splat” marking thetarget.

The projectile core 10 may also be heat treated such as by hot rollers38, shown in FIG. 10. The projectile core 10 is turned on the hotrollers 38 for a selected time at a selected temperature, until theouter surface 30 of the projectile core 10 is singed, burned, orcarbonized, forming an outer layer 32 as previously discussed. The outersurface 30 of the projectile core 10 will burn, singe, bake and/or charwhile turned on the hot rollers 38. The longer the projectile core 10 isin contact with the hot rollers 38, the thicker the outer layer 32. Theprojectile core 10 is turned on the hot rollers 38 until a desired outerlayer 32 thickness T is achieved.

In an alternate embodiment, the core mixture 14, once formed into thedesired projectile core 10 shape, is freeze dried, by rapid freezing anddrying. This step removes moisture, and produces a hardened projectilecore 10 impregnated with liquid dye 12. The freeze dried projectile core10 may then be subjected to heat, producing an outer layer 32 formedsuch as by heating, as described above.

It is appreciated that, once the outer layer 32 has been formed, theprojectile core 10 may thus be considered a finished and useableprojectile 18, and is therefore ready for use. Thus, a projectile core10 of the present invention need not be sealed or coated with gelatin orstarch compounds, as there is no need for a coating in order to retainthe shape of the projectile core 10.

However, it may be desirable to coat the projectile core 10, as shown inFIG. 11, with an outer coating 40, which may act as a sealant,protectant, or simply to present a finished cosmetic appearance of theprojectile. Gelatin compositions, starch compositions, wax compositions,or plastic compositions may be used in forming the outer coating 40. Forexample, outer coating 40 can be made from hydrophilic colloidalmaterials such as, but not limited to, gelatin, albumin, gum arabic,alginate, casein, agar or pectins, acceptable substitutes, orcombinations of those materials. Outer coating 40 could also be madefrom a synthetic organic compound such as, but not limited to,polystyrene, polypropylene, polyethylene, poloycarbonate, polyamide,polysulfane or polyvinylchloride.

Preferably, the outer coating 40 is formed from albumin, or a mixture ofalbumin and other suitable materials, which is applied to the projectilecore 10. The outer coating 40 may be applied in any acceptable manner,such as through soaking or dipping in a bath, spraying, and/or rollers.The outer coating 40 will conform to the predetermined core shape of theprojectile core 10.

The outer coating 40 is capable of protecting the projectile core 10until the projectile 18 is fired and impacts a target. The outer coating40 provides resistance to projectile core breakage prior to being firedfrom a projectile marker, and impacting a target. Unlike knownprojectiles formed as the joining of two gelatin or starch spherehalves, the coated projectile 18 of the present invention can be formedhaving no seam to disturb the projectiles flight when fired at a target.

Several properties of the projectile core 10 of the present inventioncan be controlled and manipulated in order to alter the characteristics,makeup and performance of a projectile formed utilizing the projectilecore 10 of the present invention. For example, the degree the corematerial 12 is ground, pulverized, compacted, or granulated, can becontrolled to alter the particle size and/or porosity. The degree theprojectile core 10 is compacted during formation can be controlled inorder to alter the density. Where the carrier 12 is molded prior to theaddition of colorant 14, the denser the core, the less the colorant 14will permeate through the carrier 12. The viscosity, flexibility,dampness, dryness, or other properties, of the inner portion 36 can alsobe controlled in order to alter the amount of amount of wet or soggy“splatter” when a target is struck with the projectile 18. The amountthe carrier 12 and colorant 14 are dried may also be controlled. Thegranular size of the particles of carrier 12, such as rice straw, can becontrolled to alter the absorption properties, and therefore the finalweight of the projectile formed with the core of the present invention.

Because of the various properties that can be easily and efficientlycontrolled when making a projectile core of the present invention, it isappreciated that a projectile formed according to the present inventioncan be of any size and weight required by a projectile marker.

Powder Core

In a further embodiment of the present invention, FIGS. 12 and 13 depicta projectile core 42 comprising a base powder material 44 as thecarrier. Examples of acceptable base powder materials 44 include, butare in no way limited to, calcium carbonate, chalk (calcite), zinc oxideor talc, fullers earth, kaolin, starch, gums, colloidal silica, bismuthoxychloride, titanated mica, silica, polymethylmethacrylate, micronizedTEFLON, boron nitride, acrylate copolymers, aluminum silicate, aluminumstarch octenylsuccinate, bentonite, calcium silicate, cellulose, cornstarch, diatomaceous earth, fuller's earth, glyceryl starch, hectorite,hydrated silica, kaolin, magnesium aluminum silicate, magnesiumtrisilicate, maltodextrin, montmorillonite, microcrystalline cellulose,rice starch, mica, titanium dioxide, zinc laurate, zinc myristate, zincroninate, alumina, attapulgite, calcium silicate, dextran, nylon, silicasilylate, silk powder, nylon spheres, ceramic spheres, synthetic polymerpowders, powdered natural organic compounds such as ground solid algaes,encapsulated and unencapsulated grain starches, mixtures or combinationsof any of these materials, or acceptable substitutes. The base powdermaterial 44 may have absorbent properties, adsorbent properties, orcombinations of each of these properties.

A colorant 46 is preferably added to the base powder material 44. Abinder which may be a solid, semi-solid, or liquid, can also be added tothe base powder material to assist in molding the material into thedesired shape. In some cases, it is appreciated that the base powdermaterial 44 may have a natural color, even without the addition of acolorant. In that case, the base powder material 44 may be mixed with asuitable binder, and formed into a projectile core according to thepresent invention.

The colorant may take the form of liquid dye, as discussed above, ormake take the form of a pigment. For example, lake dyes, micas orpearls, iron oxides, titanium oxides, calcium carbonates, treatedpigments, and mixtures thereof, may be mixed with the base powder toform a colored mixture for use as the core mixture. Organic pigmentsinclude aromatic dyes such as azo, indigo, triphenylmethane,anthraquinone, and xanthine dyes which are designated as D&C and FD&Cblues, browns, greens, oranges, reds, yellows and so forth. Organicpigments also include insoluble metallic salts of certified coloradditives, lakes. Inorganic pigments include iron oxides, ultramarines,chromium, chromium hydroxide colors and mixtures of these materials. Allof these would be considered suitable colorants.

In order to form the core, any of the methods discussed above may beused. Further descriptions of acceptable methods follow. In one method,the base powder material 44 is selected so as to be compactable in itsdry state. Any conventional molding operation case be used to form theprojectile core. For example, the base powder material 44 could bepoured into a first mold cavity and then compacted with a second moldcavity into the predetermined core shape. The pressure applied by themold compresses the base powder material 44 and any added binder orexcipients, into the substantially firm projectile core. Depending onthe compressibility of the selected base powder material 44, an outercoating may or may not be needed.

The base powder material 44 (with or without added ingredients) or coremixture 52 may be mixed with a suitable binder. The base powder material44 (with or without added ingredients) or core mixture 52 may then beinjected or otherwise channeled into a mold cavity where the material isformed into a predetermined core shape. The base powder material 44(with or without added ingredients) or core mixture 52 is then cured, asdescribed above, until it is substantially firm.

A first method to form a projectile core 42 from a base powder material44, shown in FIG. 14, utilizes a base powder material 44 that iscompactable in its dry state. Any conventional molding operation can beused to form the projectile core 42. The base powder material can bepoured into a first mold cavity 48 and then compacted with a second moldcavity 50 to form the desired shape.

Another method of forming the base powder material 44 projectile core isby the preparation of a damp core mixture 52 of base powder material 44combined with a colorant 46. In this embodiment, the core mixture 52 maybe further mixed with a suitable binding agent to form a pourable,moldable core mixture 52. As shown in FIG. 15, this core mixture 52 isthen injected or directed into a mold cavity 56 where the core mixture52 forms the desired shape. The molded projectile 54 (FIG. 16) isallowed to dry or cure by ambient or heated air. Alternatively, the moldcan be heated to cause the mixture to set. It is also contemplated thata drying agent can be added to the core mixture 52, e.g., silica,calcium chloride, etc.

The projectile core formed with a base powder material 44 may be coatedwith an outer coating, as discussed above.

It is appreciated that, once a cellulosic material is ground,granulated, or pulverized, it may comprise a powdery substance. Thus,“powder” as used herein therefore encompasses the cellulosic materialsthat have been dried and ground into powder, previously discussed, aswell the base powder material discussed.

It is appreciated that those skilled in the art would be readily capableof selecting suitable materials for the preparation of the projectilecore and projectile of the present invention based on the presentdisclosure.

The projectile core and projectile described herein are most preferablyintended for use as a paintball in the sport of paintball. Markingprojectiles such as paintballs must maintain their shape and integrityduring firing from, for example, compressed gas powered paintballmarkers. Such paintballs then must at least partially disintegrate ordisperse upon impact with a target at impact velocity, namely, the speedat which the paintball strikes a target such as a human paintball sportplayer equipped with the appropriate protective gear. Known paintballsthat are essentially capsules filled with liquid must break, rupture, orother disperse the liquid dye upon impact at ranges of between 25 to 300feet, with the ideal range being between 50-100 feet. Accordingly, it isappreciated that the projectile core and projectile of the presentinvention are preferably formed to meet the parameters necessary for usein the sport of paintball.

Paintball markers may have a muzzle speed of between approximately 175to 500 fps, with the preferred muzzle velocity being approximatelybetween 250-350 fps. In paintball sport competitions, the velocity atwhich a paintball marker fires a paintball from its barrel is sometimeslimited to 300 fps or less to protect the paintball sport players fromharm. The impact velocity of a paintball, the speed at which the markingprojectile hits a target, for example, a human paintball sport playerwearing the appropriate protective gear, is generally less than themuzzle velocity, but greater than 50 fps to be effective. The projectilecore and projectile of the present invention are preferably formed toretain the predetermined core shape under the conditions of the muzzlevelocities described herein, and at least partially disintegrate ordisperse upon impacting a target at the described impact velocity, inorder to present a colored “mark” or “splat” comparable to the mark madeupon impact of known liquid dye filled paintballs.

One of the benefits that can be provided by the present invention isdimensional stability. Using the present invention, the new projectilecore and/or projectile can be made to hold a favorable shape forprojectile flight more closely than existing projectiles because it isshaped by the projectile core, and not the shell or coating. An existingprojectile is an elastic material filled with a liquid, that isdeformable. This means that during shipment and storage an existingprojectile can and will change shape. The change in dimension willadversely effect loading and flight of the ball. Breakage is also anissue. A projectile made according to the present invention issubstantially firm and will resist deformation under transport andstorage. The substantially firm shape is produced during manufacturingand can be formed in a consistent way with existing machinery.

Another benefit of the present invention is the ability to controlcarrier characteristics, core mixture characteristics, and projectileshape. During manufacture, fibrous materials can be added to the mixtureof solids. By changing the type, length, thickness, weave and/or amountof these fibers the strength of the projectile and resistance tobreakage can be controlled. The shape of the projectile can also becontrolled using similar methods.

It is understood that the present invention is not limited to theparticular embodiments shown and described herein, but that variouschanges and modifications may be made without departing from the scopeand spirit of the invention.

1. A method of forming a paintball, said method comprising: forming adesired quantity of paintball filling material into an approximatelysphere-like shape; hardening the sphere-like shaped paintball fillingmaterial; and applying a shell material to the hardened sphere-likeshaped paintball filling material.
 2. The method according to claim 1,wherein hardening the filling material comprises drying the fillingmaterial.
 3. The method of forming a paintball according to claim 1,wherein forming the desired quantity of paintball filling material intoan approximately sphere-like shape comprises injecting the fillingmaterial into a spherical mold cavity.
 4. A method of forming apaintball, said method comprising: forming a quantity of paintballfilling material into a desired shape; drying the paintball fillingmaterial; and applying a shell material to the paintball fillingmaterial.
 5. The method according to claim 1, wherein applying a shellmaterial to the paintball filling material comprises spraying the shellmaterial onto the frozen paintball filling material.
 6. The methodaccording to claim 1, wherein the paintball filling material is moldedinto the desired shape.
 7. The method according to claim 1, whereinapplying a shell material to the paintball filling material comprisesdipping the paintball filling material into a bath containing the shellmaterial.
 8. The method according to claim 1, wherein applying a shellmaterial to the paintball filling material comprises pouring the shellmaterial on the paintball filling material.
 9. The method according toclaim 1, wherein forming a desired quantity of paintball fillingmaterial into a desired shape comprises pouring the paintball fillingmaterial into a mold cavity.
 10. The method according to claim 1,further comprising curing the shell material.
 11. A method of forming apaintball, said method comprising: dispensing a desired quantity ofpaintball filling material; forming the desired quantity of paintballfilling material into a desired shape; curing the paintball fillingmaterial having the desired shape to retain the desired shape and toprovide a desired size; and applying a shell material to the paintballfilling material.
 12. The method according to claim 11, wherein formingthe desired quantity of paintball filling material into a desired shapecomprises molding the paintball filling material into an approximatelyspherical shape.
 13. The method according to claim 11, wherein thedesired size is approximately 0.68 inches in diameter.
 14. The methodaccording to claim 11, wherein applying a shell material to thepaintball filling material comprises spraying the shell material ontothe paintball filling material.
 15. The method according to claim 11,wherein the paintball filling material is molded into the desired shape.16. The method according to claim 11, wherein applying a shell materialto the paintball filling material comprises dipping the paintballfilling material into a bath containing the shell material.
 17. Themethod according to claim 11, wherein the projectile is generallyliquid-free.
 18. The method according to claim 11, wherein forming aquantity of paintball filling material into a desired shape comprisespouring the paintball filling material into a mold cavity.
 19. Themethod according to claim 11, wherein the desired shape is a sphereapproximately 0.68 inches in diameter.
 20. The method according to claim1, wherein the filling material is cured.